Winch Safety Device for Rope Layer Radius Control
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Solution Overview
Problem
Existing hydraulic systems for winches do not effectively allow for safe and reliable termination of load pulling and simple interruption of electric and/or hydraulic circuits when the radius of the wound rope on the drum increases due to inaccurate winding, leading to potential overloading.
Innovation Solution
A mechanic-hydraulic system incorporating a check valve, pressure regulator, and a rod with variable length to activate a switch for turning off the electric circuit or a mechanically controlled hydro-valve to shut off the hydraulic circuit when a pre-defined outer radius of rope coils is reached, ensuring safe winding termination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If the radius of the wound rope on the drum increases due to inaccurate winding, then the pulling force decreases, but the system reliability deteriorates due to potential overloading
Solution Approach 1:
The patent implements a safety device that performs preliminary detection of the rope layer outer radius before overloading occurs. The detector continuously monitors the radius and triggers a switch-off mechanism at a predetermined safe radius, preventing the pulling force from decreasing and eliminating the risk of overloading before it can affect system reliability.
Solution Approach 2:
The patent employs a feedback mechanism where a detector monitors the outer radius of the wound rope layers and provides continuous information to a control system. When the radius reaches a predetermined value, the system automatically interrupts the electric or hydraulic circuit, creating a closed-loop control that maintains both pulling force and system reliability.
2Reliability
If a safety device is added to switch off winding at a pre-defined border size, then the system reliability improves, but the device complexity increases
Solution Approach 1:
The patent extracts the safety function as a separate, modular device that can be added to existing winch systems. The safety device includes a detector, a switching mechanism, and a reference element, which can be integrated into the existing electric or hydraulic circuit without fundamentally redesigning the entire system, thus minimizing the increase in device complexity while improving reliability.
Solution Approach 2:
The patent introduces an intermediary switching mechanism that acts as a mediator between the detector and the main drive system. This switch-off device (electric or hydraulic) serves as an intermediary element that translates the detector's radius measurement into a control action, simplifying the overall system architecture while ensuring reliable operation.
3Adaptability or versatility
If the rod length is made variable to adjust the switching radius, then the adaptability improves, but the device complexity increases
Solution Approach 1:
The patent implements a variable rod length mechanism that allows dynamic adjustment of the switching radius threshold. The rod can be extended or retracted to different lengths, enabling the system to adapt to different rope diameters and winding configurations. This dynamic adjustment capability is achieved through a simple mechanical extension mechanism that integrates with the existing detector assembly.
Solution Approach 2:
The patent designs the variable rod length mechanism to serve multiple functions: it adjusts the switching radius threshold, maintains mechanical contact with the detector, and provides structural support. This multi-functional design allows the same component to achieve adaptability while minimizing the addition of separate adjustment mechanisms, thereby limiting the increase in device complexity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables safe and reliable switching off of the winch winding at a constant or variable pulling force, preventing overloading by linearly increasing oil pressure with the radius of rope layers and triggering a switch or hydro-valve to interrupt the circuit, thus maintaining operational safety.
Implementation Method 1
linearly increasing oil pressure with the radius of rope layers
Implementation Method 2
The hydraulic system includes a check valve and a pressure regulator
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
A safety device for switching off winding of a cable rope of a winch at a constant or variable pulling force is disclosed wherein a mechanic-hydraulic system with a pressure regulator (21) is equipped with a rod (36) and an extension (37) with an adjustable length »i« for precise setting of the pulling force; that the extension (37) is located from a switch (38) at an adjustable distance »j«, the switch (38) being connected in parallel to the circuit of the winding function of the winch; that in the case a rope layer exceeds an outer radius »rz«, a cylinder (33) through forks (34) retracts for a pre-specified border value the extension (37) in regards to a drum (30), wherein the extension (37) activates the switch (38), which causes interruption of the electric and/or hydraulic circuit of active winding function. Switching off winding of the cable rope may also be executed with a mechanically controlled hydro-valve, which is connected into the primary hydraulic scheme of a winch and enables switching off the hydraulic circuit after reaching the border value of the radius »rz«.